1996 225 Mercury Offshore (carb)

[Fletch170]

Hey guys,

working this thing out, looks like the PO replaced the starter and trim relays with a more modern version. They are no longer inside the little plastic cowl, but simply hanging there, zip tied, as seen below:



The old relays, where they should be have been removed, as seen below:



I found two threaded mounting points coming from the block, I actually found the correct thread stainless allen bolt and mounted them directly to the block. Is this OK? They wont fit where the originals were. Will they be OK where I put them? They are rubber mounted.... Please take a look.

[seabob4]

Nothing wrong with that, Christian...

[Fletch170]

Cool,

Thanks Bob. Also, looking at the block, is Mercury is pretty sparce with the paint? Either that, or my block was painted at 4:55 on a Friday. Just wondering.....

A few other things.

The tiller is rusted, chipped off the rust. Looks like hell, but the cast iron is solid. Should I be concerned? Looks like to replace this, the lower and mid section needs to come completely off.

Also, the lower steering mounts are rusted, and the plastic bushings have hairline cracks. Is this just superficial? Ill follow up with pictures.

[Fletch170]

S@it.

[Fletch170]

On a side note, anyone want to sell me a mid section??????

[Mullady76]

The tiller is rusted, chipped off the rust. Looks like hell, but the cast iron is solid. Should I be concerned? Looks like to replace this, the lower and mid section needs to come completely off.

How rusted is the bottom of the swivel pin where it attaches to the yoke?  Mine was so rusty the splines were falling apart.  Also make sure the (2) bolts that secure to motor to the top of the pin are in good condition.  
To change this the power head needs to be removed.  I bought a used one from a freshwater motor on ebay for cheap.  The new "updated" parts are all stainless steel and very expensive.

[fitz73222]

Fletch,

There is no aftermarket way out of this. It's either new or used freshwater replacement. First, start to cross reference part number use across different models. Yours is a 3.0 liter engine which would include later Opti-Max units which opens up availabilty of parts. The steering arm and pivot shaft are an assembly. A freshwater unit would be the best bet, but can get pricey since an entire mid usually includes the trim system. I would think a good used mid with trim is going to get you into $600- $700. I would price new parts against that number and see how it shakes out. Start to cross reference part numbers on marineengine.com or ishopmarine.com and get an idea of the models you can choose from and start shopping.

[Fletch170]

The mid section yoke bolts are really rusted, and the mid section plastic bushings have cracks....these need to be replaced. Can I do this without removing the mid section?

The other issue is....the goddamn trim release valve (the nylon screw) is all buggered, and stuck.

Here is the deal, the tiller is in Ok shape as are the upper bolts. The bottom hardware is shot, as are the bushings, as is the trim release screw. Assuming I can simply replace these for a reasonable costs, I'd rather do that. However, this involves be drilling out the nylon screw (yikes). Is it easier to just replace the whole damn thing?

[Fletch170]

DAMN YOU EBAY!!!!

Offered the guy half of what he was asking and he took it. looks like she's coming apart....

http://www.ebay.com/itm/221450738072?_t ... 552wt_1238

[fitz73222]

Good deal, assuming the corrosion is at bay coming from Rhode Island. Looks like a 25" mid. If you are 25" just bolt up your powerhead and gearcase to it and go. If your 20", do the changeover of the components you need since the swivel pin and trim are the same and the extra 5" is in the midsection casting which you dont need anyway.

[Fletch170]

Actually worked a deal for free shipping and he can keep the mid section casting, as I don't need it. $600 bills to fix all the issues, seemed like the way to go.

[Fletch170]

I'm assuming I'll take the lower unit off first, then the powerhead?

i can only assume a gasket kit is now in order? At least the gasket for where the block mates to the mid? If anyone has the correct process or tips for doing this, please let me know.

According to the PO the water pump was changed, as was the seal........I think I should drain anyway and look for water. Being that the rest of this motor is slapped together.

it is, however, under the cowl......spotless, and has perfect 120 PSI on all 6. So I guess I can't be that pissed. Spent 3 g's shipped from Miami, which included all controls and oil tank.

Doing a once over, what should I replace as preventative maint? The alternator belt? Anything to look for? Since this thing is coming apart, will I have access to the oil pump gear?

Merc people, I need pointers!

[fitz73222]

Actually worked a deal for free shipping and he can keep the mid section casting, as I don't need it. $600 bills to fix all the issues, seemed like the way to go.

Ok, so you get the stern brackets, trim system, swivel pin, swivel housing and yoke? You did fine for $600 with free shipping! You'll need a powerhead base gasket, a light coat of some non-hardening gasket compound to coat the mating surfaces on either side of the gasket. I do not recommend changing the oil pump unless she has a ton of hours on her plus that pump runs about $300 without the crankshaft gear which you can only replace after you pull the bottom crankshaft ball bearing which is pressed in place.

[Fletch170]

Sounds good, i read through the service manual, and it actually seems pretty "easy". Looked on ebay, and it seems I need to buy a whole gasket kit to get that one powerhead base gasket. Anyone know where I can get it by itself?

[fitz73222]

Sounds good, i read through the service manual, and it actually seems pretty "easy". Looked on ebay, and it seems I need to buy a whole gasket kit to get that one powerhead base gasket. Anyone know where I can get it by itself?

You will need the serial number for the correct version gasket. I buy just about everything from these guys now.
http://www.marineengine.com/parts/mercu ... aust-plate